Packaging and method of packaging uniform ice objects

ABSTRACT

A method of manufacturing uniform ice objects includes placing an ice block in a freezer; cutting the ice block into sub-blocks, in the freezer; trimming all sides of each sub-block to ensure smooth, straight cuts on all sides thereof, in the freezer; cutting each trimmed sub-block into sheets, in the freezer, to define a final height of ice objects; cutting each sheet into loins, in the freezer, to define a width of the ice objects; cutting each loin into the ice objects, in the freezer; loading the ice objects in tubs, in the freezer; relocating the tubs of ice objects from the freezer to a refrigerator; removing snow from the ice objects and packaging the ice objects, in the refrigerator; and returning the packaged ice objects to the freezer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Prov. Pat.App. No. 62/613,630, filed Jan. 4, 2018, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

This application generally relates to ice and, in particular, to asystem, method and apparatus for manufacturing shaped ice.

STATEMENT OF FEDERALLY FUNDED RESEARCH

None.

BACKGROUND OF THE DISCLOSURE

Conventional ice making machines produce ice cubes or other ice shapesthat typically are not transparent and clear due to the presence oftrapped bubbles. Moreover, the uniformity of the ice made byconventional ice making machines usually lacks precision. Although thesedesigns are workable, improvements in the quality and consistency ofshaped ice continue to be of interest.

SUMMARY OF THE DISCLOSURE

Embodiments of a system, method and apparatus for manufacturing shapeice objects is disclosed. For example, a method of manufacturing uniformice objects can include placing an ice block in a freezer; cutting theice block into sub-blocks, in the freezer; trimming all sides of eachsub-block to ensure smooth, straight cuts on all sides thereof, in thefreezer; cutting each trimmed sub-block into sheets, in the freezer, todefine a final height of ice objects; cutting each sheet into loins, inthe freezer, to define a width of the ice objects; cutting each loininto the ice objects, in the freezer; loading the ice objects in tubs,in the freezer; relocating the tubs of ice objects from the freezer to arefrigerator; removing snow from the ice objects and packaging the iceobjects, in the refrigerator; and returning the packaged ice objects tothe freezer.

The foregoing and other objects and advantages of these embodiments willbe apparent to those of ordinary skill in the art in view of thefollowing detailed description, taken in conjunction with the appendedclaims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of theembodiments are attained and can be understood in more detail, a moreparticular description can be had by reference to the embodimentsthereof that are illustrated in the appended drawings. However, thedrawings illustrate only some embodiments and therefore are not to beconsidered limiting in scope as there can be other equally effectiveembodiments.

FIG. 1 is a schematic, isometric view of an ice block.

FIGS. 2-4 are schematic drawings of embodiments of product and methodsteps for manufacturing shaped ice.

FIG. 5 is a schematic drawing of an embodiment of a tool for the methodof manufacturing shaped ice.

FIGS. 6-9 are schematic drawings of embodiments of other product andmethod steps for manufacturing shaped ice.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION OF THE DISCLOSURE

FIGS. 1-9 depict embodiments of a system, method and apparatus formanufacturing high purity, highly uniform ice objects (such as icecubes), is disclosed. The drawings are schematic and sizes of thevarious components shown in the drawings are not to scale. In anexample, FIGS. 1-9 illustrate equipment and a process having a firststep of receiving very high purity ice blocks 11. The ice blocks 11 canbe formed from a machine that uses reverse osmosis, filtered waterhaving extremely high purity and extremely low air content (e.g., smallair pockets, such as bubbles). In one version, such a machine can beproduced by Clinebell Equipment Company of Loveland, CO. Examples of theice blocks 11 can be large and each weigh at least 100 pounds. In anexample, each ice block 11 can weigh about 300 pounds, and havedimensions of about 40 inches in length, by about 20 inches wide, byabout 10 inches in height.

As shown in FIGS. 1 and 2, the ice blocks 11 are received and placed ina room comprising a freezer 13, such as on a platform 15. In someexamples, the ice blocks 11 are allowed to temper in the freezer for atleast about 12 hours. Tempering allows the ice blocks 11 to reach atemperature at which it is safe to cut into smaller pieces. For example,the temperature of freezer 13 can be about 10° F. The temperature of thefreezer 13 can be tightly controlled during the process, such as about+/−5° F., or about 5° F. to about 15° F.

Each ice block 11 can be carefully measured and divided into two or moresub-blocks 17 (FIG. 3) while in the freezer 13. For example, one iceblock 11 can be divided into three sub-blocks 17. In one version, theice block 11 is manually cut into the sub-blocks 17 with a chainsaw,such as an electric chainsaw by Stihl Inc. of Virginia Beach, Va.

The sub-blocks 17 can then be placed on a band saw 19 (FIG. 4) locatedinside the freezer 13. An example of the band saw 19 can comprise a BiroModel 3334 Power Meat Cutter of Marblehead, OH. The band saw 19 can beused to trim all six sides of the sub-block 17 to ensure smooth,straight cuts on all six sides of the sub-block 17. Such trimming alsocan remove and/or eliminate any irregularities or curvature in thesub-block 17. In addition, the band saw 19 can include one or more(e.g., two arrays of two) blade cleaners 20 (FIG. 5) for its blade 22.One blade cleaner 20 can be located adjacent to each side of the cuttingarea of the blade 22 of the band saw 19. The blade cleaners 20 can bearrayed in opposed pairs on opposite sides of the blade 22, as shown.Examples of the blade cleaners 20 can comprise a polymer or plastic(e.g., nylon), such as Nyleen Biro blade cleaners, Model B004-131N fromDavison's Butcher Supply of Commerce, Calif. In some embodiments,metallic blade cleaners are not used in the process.

In a next step of the process, each trimmed sub-block 17 is cut by theband saw 19 into two or more sheets 21 (FIG. 6) while inside the freezer13. Each sheet 21 can comprise a final “height” of the shaped ice objectthat it will ultimately form. For example, the final height can be theheight of the ice cubes 25 shown in FIG. 8. This process can ensure thatall ice objects are cut to substantially the exact same height, insteadof adjusting the band saw 19, which could potentially and inadvertentlyvary the height.

The process may further include cutting each sheet 21 into two or moreloins 23 (FIG. 7) with the band saw 19 in the freezer 13. Each loin 23can be substantially identical in height (as noted above for sheets 21)as well as width. The width can be the final width of the ice objects,such as the width of the ice cubes 25, that ultimately will be formed.

Embodiments of the process can further include cutting each loin 23 intotwo or more ice cubes 25 (FIG. 8) with the band saw 19 in the freezer13. Each ice cube 25 can be substantially identical in height, width andlength. For example, each of the height, width and length can be anydesired dimensions. In some versions, the shaped objects can be squarecubes or rectangular cubes. For example, the shaped object can be astandard cube having 2 inch sides, a whiskey cube having 1.8 inch sides,a double rock having dimensions of 2 inches by 2 inches by 2.5 inches,or a Collins shaped ice object having dimensions of 1.25 inches by 1.25inches by 5 inches. The variances of size of the respective ice objectscan be minimal, and adjustments to the process and equipment are madethroughout the method to ensure that the desired, respective ice objectsare as identical as possible. For example, dimensionally, the final iceobjects can vary from each other by not greater than about 0.1 inches orless, in any dimension, such as with respect to any other same type ofice cube 25 formed from loins 23.

In addition, each cutting procedure described herein can comprise usinga food grade white oil or butcher's oil to lubricate the cutting bladesduring each step. The use of white oil can reduce the amount of time ittakes to make each cut. In addition, the white oil can be applied to abottom wheel of the band saw 19 to avoid snow build up during cutting ofthe ice. Such oil can meet or exceed both FDA and USDA requirements, andleave little to no residue on the final ice products.

While in the freezer 13, the ice cubes 25 can be placed in tubs 27 andstocked until they are ready to be packed. The ice cubes 25 are notover-stacked or over-filled in the tubs 27 to avoid sticking between theice cubes 25 with pressure and time. For example, the tubs 27 cancomprise restaurant grade bus tubs having a volume of about 10 to 12gallons. Such tubs 27 can hold about only 40 to 50 pounds of ice cubes25, again to help prevent them from sticking. The ice cubes 25 remain inthe tubs 27 for a minimal amount of time (e.g., no more than about 30minutes) prior to packing.

Subsequent steps of the process can take place outside of the freezer13, such as in a room comprising a refrigerator 31. For example, thetemperature of the refrigerator 31 can be about 38° F. In some versions,the temperature of the refrigerator 31 can be tightly controlled, suchas about +2° F. to about −5° F., or about 40° F. to about 33° F.

Once the tubs 27 of ice cubes 25 are placed in the refrigerator 31, theice cubes 25 can be brushed for excess snow present from the cuttingprocess. The warmer temperature of the refrigerator 31 (relative to thefreezer 13) can facilitate the snow removal process since the snow tendsto stick to the ice cubes 25 in the freezer 13. The ice cubes 25 alsoare inspected for quality and then packaged. The packing and packagingcan take place in the refrigerator 31 or, alternatively, in the freezer13. The time between removing the freshly cut ice cubes in tubs 27 fromthe freezer 13, to returning the packed and packaged ice cubes 25 to thefreezer 13 is minimal, such as no more than about 30 to 45 minutes.

Embodiments of the ice cubes 25 can be carefully packed in food gradepoly-press containers. For example, the food grade poly-press containerscan include a corrugated box 41, divider boards or dividers 43 toseparate each individual ice cube 25 in length and width directions, andpads 45 to separate vertical layers of the ice cubes 25 in the dividers43 in the corrugated box 41. Such arrangements can prevent stickingbetween the ice cubes 25 inside corrugated box 41.

Versions of the food grade poly-press containers can include a selectedrange of thickness of food grade wax coating. For example, the foodgrade wax coating can have a thickness of about 0.003 inches to about0.009 inches, such as about 0.006 inches, on each surface that contactsthe ice. At least one surface of each of the corrugated boxes 41,dividers 43 and pads 45 can include this thickness of food grade waxcoating. Such wax thicknesses can exceed both FDA and USDA requirements.The overall thickness of each wall of the dividers 43, including thefood grade wax coating(s), can be about 0.02 inches to about 0.06inches, such as about 0.04 inches.

Other versions can include one or more of the following embodiments.

1. A method of manufacturing uniform ice objects, comprising:

(a) placing an ice block in a freezer;

(b) cutting the ice block into sub-blocks, in the freezer;

(c) trimming all sides of each sub-block to ensure smooth, straight cutson all sides thereof, in the freezer;

(d) cutting each trimmed sub-block into sheets, in the freezer, todefine a final height of ice objects;

(e) cutting each sheet into loins, in the freezer, to define a width ofthe ice objects;

(f) cutting each loin into the ice objects, in the freezer;

(g) loading the ice objects in tubs, in the freezer;

(h) relocating the tubs of ice objects from the freezer to arefrigerator;

(i) removing snow from the ice objects and packaging the ice objects, inthe refrigerator; and then

(j) returning the packaged ice objects to the freezer.

2. The method of any of these embodiments, wherein step (a) furthercomprises tempering the ice blocks in the freezer for at least about 12hours.

3. The method of any of these embodiments, further comprisingmaintaining the freezer at a temperature of at least about 5° F. and notgreater than about 15° F.

4. The method of any of these embodiments, further comprising formingthe ice objects with respective dimensions that vary from each other bynot greater than about 0.1 inches.

5. The method of any of these embodiments, wherein step (b) comprisescutting with an electric chain saw.

6. The method of any of these embodiments, wherein steps (c) through (f)comprise cutting with a band saw.

7. The method any of these embodiments, wherein steps (c) through (f)comprise cleaning a blade of the band saw with polymer blade cleaners onopposed sides of the blade.

8. The method any of these embodiments, wherein steps (c) through (f)comprise lubricating the blade with a food grade white oil.

9. The method of any of these embodiments, wherein step (g) comprisesloading no more than about 50 pounds of the ice objects in each tub.

10. The method of any of these embodiments, wherein steps (g) and (h)comprise retaining the ice objects in the tubs for not greater thanabout 30 minutes prior to packing.

11. The method of any of these embodiments, wherein steps (h) and (i)comprise retaining the ice objects in the refrigerator for not greaterthan about 45 minutes.

12. The method of any of these embodiments, further comprisingmaintaining the refrigerator at a temperature of at least about 33° F.and not greater than about 40° F.

13. The method of any of these embodiments, wherein step (i) comprisespacking the ice objects in food grade poly-press containers comprisingboxes, dividers in the boxes to separate horizontally adjacent ones ofthe ice objects, and pads in the boxes to separate vertically adjacentones of the ice objects.

14. The method of any of these embodiments, further comprising providingeach ice-contacting side of the food grade poly-press containers with afood grade wax coating having a thickness of about 0.003 inches to about0.009 inches.

15. The method of any of these embodiments, further comprising providingeach divider with walls, and each wall comprises an overall thickness,including the food grade wax coatings, of at least about 0.02 inches andnot greater than about 0.06 inches.

16. A method of manufacturing uniform ice objects, comprising:

(a) placing an ice block in a freezer;

(b) cutting the ice block into sub-blocks, in the freezer;

(c) trimming all sides of each sub-block to ensure smooth, straight cutson all sides thereof, in the freezer;

(d) cutting each trimmed sub-block into sheets, in the freezer, todefine a final height of ice objects;

(e) cutting each sheet into loins, in the freezer, to define a width ofthe ice objects;

(f) cutting each loin into the ice objects, in the freezer;

(g) loading the ice objects in tubs, in the freezer;

(h) removing snow from the ice objects and packaging the ice objects;

(i) wherein steps (c) through (f) comprise cleaning a blade of the bandsaw with polymer blade cleaners on opposed sides of the blade, andlubricating the blade with a food grade white oil.

17. The method of any of these embodiments, wherein step (a) furthercomprises tempering the ice blocks in the freezer for at least about 12hours; and the method further comprises:

maintaining the freezer at a temperature of at least about 5° F. and notgreater than about 15° F.;

maintaining the refrigerator at a temperature of at least about 33° F.and not greater than about 40° F.; and

forming the ice objects with respective dimensions that vary from eachother by not greater than about 0.1 inches.

18. The method of any of these embodiments, wherein step (b) comprisescutting with an electric chain saw, steps (c) through (f) comprisecutting with a band saw, and step (g) comprises loading no more thanabout 50 pounds of the ice objects in each tub.

19. A method of manufacturing uniform ice objects, comprising:

(a) placing an ice block in a freezer;

(b) cutting the ice block into sub-blocks, in the freezer;

(c) trimming all sides of each sub-block to ensure smooth, straight cutson all sides thereof, in the freezer;

(d) cutting each trimmed sub-block into sheets, in the freezer, todefine a final height of ice objects;

(e) cutting each sheet into loins, in the freezer, to define a width ofthe ice objects;

(f) cutting each loin into the ice objects, in the freezer;

(g) loading the ice objects in tubs, in the freezer;

(h) removing snow from the ice objects and packaging the ice objects infood grade poly-press containers comprising boxes, dividers in the boxesto separate horizontally adjacent ones of the ice objects, and pads inthe boxes to separate vertically adjacent ones of the ice objects; and

(i) providing each ice-contacting side of the food grade poly-presscontainers with a food grade wax coating having a thickness of about0.003 inches to about 0.009 inches, providing each divider with walls,and each wall comprises an overall thickness, including the food gradewax coatings, of at least about 0.02 inches and not greater than about0.06 inches.

20. The method of any of these embodiments, wherein step (a) furthercomprises tempering the ice blocks in the freezer for at least about 12hours, step (b) comprises cutting with an electric chain saw, steps (c)through (f) comprise cutting with a band saw, and step (g) comprisesloading no more than about 50 pounds of the ice objects in each tub; andthe method further comprises:

maintaining the freezer at a temperature of at least about 5° F. and notgreater than about 15° F.;

maintaining the refrigerator at a temperature of at least about 33° F.and not greater than about 40° F.; and

forming the ice objects with respective dimensions that vary from eachother by not greater than about 0.1 inches.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable those of ordinary skill inthe art to make and use the invention. The patentable scope is definedby the claims, and can include other examples that occur to thoseskilled in the art. Such other examples are intended to be within thescope of the claims if they have structural elements that do not differfrom the literal language of the claims, or if they include equivalentstructural elements with insubstantial differences from the literallanguages of the claims.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiescan be performed in addition to those described. Still further, theorder in which activities are listed are not necessarily the order inwhich they are performed.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofinvention.

It can be advantageous to set forth definitions of certain words andphrases used throughout this patent document. The term “communicate,” aswell as derivatives thereof, encompasses both direct and indirectcommunication. The term “discreet,” as well as derivatives thereof,references to the amount of skin exposed by a user of the garment,rather than the type of style of the garment. The terms “include” and“comprise,” as well as derivatives thereof, mean inclusion withoutlimitation. The term “or” is inclusive, meaning and/or. The phrase“associated with,” as well as derivatives thereof, can mean to include,be included within, interconnect with, contain, be contained within,connect to or with, couple to or with, be communicable with, cooperatewith, interleave, juxtapose, be proximate to, be bound to or with, have,have a property of, have a relationship to or with, or the like. Thephrase “at least one of,” when used with a list of items, means thatdifferent combinations of one or more of the listed items can be used,and only one item in the list can be needed. For example, “at least oneof: A, B, and C” includes any of the following combinations: A, B, C, Aand B, A and C, B and C, and A and B and C.

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural unless it is obvious that it is meant otherwise.

The description in the present application should not be read asimplying that any particular element, step, or function is an essentialor critical element that must be included in the claim scope. The scopeof patented subject matter is defined only by the allowed claims.Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect toany of the appended claims or claim elements unless the exact words“means for” or “step for” are explicitly used in the particular claim,followed by a participle phrase identifying a function.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that cancause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, can also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, can also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

1.-20. (canceled)
 21. A method of packaging uniform ice objects,comprising: (a) forming ice objects with respective dimensions that varyfrom each other by not greater than about 0.1 inches; and then (b)packing the ice objects in food grade poly-press containers comprisingboxes, dividers in the boxes to separate horizontally adjacent ones ofthe ice objects, and pads in the boxes to separate vertically adjacentones of the ice objects, wherein each ice-contacting side of the foodgrade poly-press containers comprises a food grade wax coating having athickness of about 0.003 inches to about 0.009 inches, each dividercomprises walls, and each wall comprises an overall thickness, includingthe food grade wax coating, of at least about 0.02 inches and notgreater than about 0.06 inches.
 22. The method of claim 21, wherein theice objects comprise a food grade white oil.
 23. Packaging for iceobjects, comprising: food grade poly-press containers comprising boxes,dividers in the boxes configured to separate horizontally adjacent onesof the ice objects, and pads in the boxes configured to separatevertically adjacent ones of the ice objects, wherein each ice-contactingside of the food grade poly-press containers comprises a food grade waxcoating having a thickness of about 0.003 inches to about 0.009 inches,each divider comprises walls, and each wall comprises an overallthickness, including the food grade wax coating, of at least about 0.02inches and not greater than about 0.06 inches.